Removal and Replacement
REMOVALCAUTION: The 3.2/3.5L engines are NOT a freewheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed.
1. Drain cooling system. Refer to Cooling System for procedure.
2. Remove accessory drive belts.
3. Remove crankshaft damper.
4. Remove timing belt covers and timing belt.
CAUTION: When camshaft sprocket bolts are loosened or removed, the camshafts must be re-timed to the engine. Also, the camshaft sprocket bolts must NOT be reused. Refer to camshaft timing and timing belt installation procedure.
5. Hold camshaft sprocket with 36 mm (1 7/16 inch) box wrench loosen and remove bolt and washer. To remove the bolt with engine in the vehicle it may be necessary to lift that side of the engine because the right bolt is 213 mm (8 3/8 inch) long and the left bolt is 255 mm (10.0 inch) long.
6. Remove camshaft sprocket from camshaft. Each sprocket has a D shaped hole that allows it to rotate several degrees in each direction on its shaft. This design must be timed with the engine to ensure proper performance of the engine. Refer to camshaft and timing belt installation for procedures.
TIMING PROCEDURE-3.2/3.5L
Fig. 74
CAUTION: The camshaft sprockets are not interchangeable from side to side (Fig. 73).
Fig. 74
1. Place crankshaft sprocket to the TDC mark on the oil pump housing (Fig. 74).
Fig. 79
2. Install a dial indicator in number 1 cylinder to check TDC of the piston (Fig. 79). Rotate the crankshaft until the piston is at exactly TDC.
Fig. 75
3. Install the camshaft alignment Special Tools 6642 to the rear of each cylinder head (Fig. 75).
CAUTION: Compress the tensioner slowly, as damage to the tensioner could result.
Fig. 76
4. Slowly preload the tensioner with a vise and install locking pin (Fig. 76).
NOTE: Once pin is installed, the tensioner must be stored with the plunger facing upward until it is ready to be reinstalled.
Fig. 77
5. Install camshaft sprockets onto the camshafts. Install NEW sprocket attaching bolts into place. The 255 mm (10 inch) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 inch) bolt is to be installed into the right camshaft. Do not tighten the bolts. Camshaft sprocket mark should be positioned between the marks on the cover (Fig. 77) at both sprocket.
Fig. 78
6. Install the timing belt starting at the crankshaft sprocket going in a counterclockwise direction (Fig. 78). Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. Each camshaft sprockets mark should still fall between the cover marks.
7. Holding the tensioner pulley against the belt, install the tensioner into the housing and tighten to 28 Nm (250 in. lbs.).
8. When tensioner is in place pull retaining pin to allow the tensioner to extend to the pulley bracket.
9. With number 1 piston at TDC (Fig. 79), hold the camshaft sprocket hex with a 36 mm (1 7/16 inch) wrench and tighten the camshaft bolts to 102 Nm (75 ft. lbs.) plus a 90° turn for the Right side and 115 Nm (85 ft. lbs.) plus a 90° turn for the Left side.
10. Remove dial indicator and install spark plug.
11. Remove camshaft alignment Special Tools 6642 and install cam covers and O-rings. Tighten fasteners to 28 Nm (250 in. lbs.).
12. Install timing belt covers.
13. Install crankshaft damper.
14. Install accessory drive belts.
15. Fill cooling system.
16. Start engine and allow to idle for approximately 1 minute. If a noticeable noise is present from the timing belt/tensioner, air has possibly entered the tensioner.
a. To remove air from tensioner; using a DRB III, operate the engine at speed of 1600-2000 RPM for 10 minutes. This will purge air from tensioner and noise will be dissipated.
NOTE: If air is present, the tensioner will be soft and may generate noise. This noise should disappear after no more than 15 minutes of engine running time.